Multilayer mesh structure

ABSTRACT

A multilayer mesh structure has multiple mesh layers being stacked on each other, and may have a woven sheet and a covering layer. Each mesh has multiple primary and secondary fibers. The secondary fibers are mounted crossing over and connecting to the primary fibers at multiple bonded intersections to form the mesh. The woven sheet is formed on a surface of the mesh and may be a natural or man-made fiber (such as rayon, nylon cotton or linen fibers) woven sheet. The covering layer is a film material to enclose and hold the multiple mesh layers. When the multilayer mesh structure is used as a shoe-pad or the like, the multilayer mesh structure provides a shoe with the shoe-pad better air permeability and elasticity.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a mesh, and more particularly to amultilayer mesh structure for upholstery or shoes.

2. Description of the Related Art

Conventional materials for a mattress or a seat pad, such as plasticfoam, dry grasses, coconut shell fibers or the like, are eithernon-breathable or water permeable, they are also prone to mold.

A shoe has a sole and the sole is used to enhance a breathability andelasticity of a shoe. Unfortunately, conventional materials for the soleof a shoe are heavy or water permeable.

The present invention provides a multilayer mesh structure to obviate ormitigate the shortcomings of the conventional materials for upholsteryand shoes.

SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide amultilayer mesh structure that is elastic, breathable and covered by amildew growth-preventing film, suitable for shoes or upholstery.

The multilayer mesh structure has multiple mesh layers being stacked oneach other, and may have a woven sheet and a covering layer. Each meshhas multiple primary and secondary fibers. The secondary fibers aremounted crossing over and connecting to the primary fibers at multiplebonded intersections to form the mesh. The woven sheet is formed on asurface of the mesh and may be a natural or man-made fiber (such asrayon, nylon cotton or linen fibers) woven sheet. The covering layer isa film material to enclose and hold the multiple mesh layers.

Other objectives, advantages and novel features of the invention willbecome more apparent from the following detailed description when takenin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a multilayer mesh structure inaccordance with the present invention;

FIG. 2 is an exploded perspective view of a first embodiment of themultilayer mesh structure in FIG. 1;

FIG. 3 is an enlarged perspective view of a mesh layer in FIG. 1;

FIG. 4 is a perspective view of a second embodiment of the multilayermesh structure in accordance with the present invention;

FIG. 5 is an exploded perspective view of the multilayer mesh structurein FIG. 4;

FIG. 6 is an enlarged perspective view of a mesh in FIG. 4;

FIG. 7 is a perspective view of a third embodiment of the multilayermesh structure in accordance with the present invention;

FIG. 8 is an enlarged perspective view of a mesh layer in FIG. 7;

FIG. 9 is a perspective view of a fourth embodiment of the multilayermesh structure in accordance with the present invention;

FIG. 10 is an exploded perspective view of the multilayer mesh structurein FIG. 9;

FIG. 11 is a perspective view of the multilayer mesh structure with acovering in accordance with the present invention;

FIG. 12 is a perspective view of the multilayer mesh structure with anassistant layer in accordance with the present invention;

FIG. 13 is a cross-sectional view of two enhanced multilayer meshstructures applied on a shoe;

FIG. 14A is an exploded perspective view of one of the enhancedmultilayer mesh structures in FIG. 13;

FIG. 14B is an enlarged perspective view of a woven sheet in FIG. 14A;

FIG. 15 is a perspective view of the enhanced multilayer mesh structuresin FIG. 14A;

FIG. 16 is an exploded perspective view of the other one of the enhancedmultilayer mesh structures in FIG. 13; and

FIG. 17 is a perspective view of the enhanced multilayer mesh structurein FIG. 16.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1, 4, 7, 9, 12, 14A, 15 and 16, a multilayermesh structure (1, 1A, 1B, 1C, 1D, 1E) in accordance with the presentinvention comprises multiple mesh layers (10, 10A, 10B), an optionalcovering layer (20), an optional assistant layer (30), and an optionalwoven sheet (13).

The mesh layers (10, 10A, 10B) are non-woven, are stacked on top of eachother, may be elastic, breathable and have a mildew growth-preventingfilm, may be thermoplastic elastomer or plastic materials made such aspolyethylene (PE), ethylene-vinyl acetate copolymer (EVA), thermoplasticelastomer (TPE) thermal plastic rubber (TPR) or the like. Each meshlayer (10, 10A, 10B) may be bonded to adjacent mesh layers by sewing oradhesion such as thermal adhesion, super sonic adhesion or the like.Each mesh layer (10, 10A, 10B) has two surfaces, multiple primary fibers(11, 11A), multiple secondary fibers (12, 12A) and multiple breathingholes formed between the primary and secondary fibers (11, 11A, 12,12A). The breathing holes may be uniform in each of the multiple meshlayers (10, 10A, 10B)

The primary fibers (11, 11A) are mounted substantially parallel to eachother, are extruded to have at least one regular cross section that maybe circular, quadrangular, hexagonal, rectangular or the like and haveat least one thickness.

The secondary fibers (12) are mounted substantially parallel with eachother, cross the primary fibers (11) at bonded intersections to form themesh layer (10, 10A, 10B) and are extruded to form at least one regularcross section that may be circular, quadrangular, hexagonal, rectangularor the like and have at least one thickness.

The multiple mesh layers (10, 10A, 10B) are stacked on top of each otherto form a multilayer mesh structure (1, 1A, 1B, 1C, 1D, 1E) having twosurfaces and two surface mesh layers respectively closest to eachsurface and at least one middle mesh layer.

With further reference to FIG. 11, the covering layer (20) is a film toenclose the multiple stacked mesh layers (10, 10A, 10B), to allow themultilayer mesh structure (1, 1A, 1B, 1C) to be implemented asupholstery such as a cushion, mattress or the like.

The assistant layer (30) may be a plastic foam, silicon foam or thelike, is soft and resilient and is bonded adjacent to at least onemultilayer mesh structure (1, 1A, 1B, 1C), and may be bonded between twomultilayer mesh structures (1, 1A, 1B, 1C) inside the covering layer(20) to further increase comfort of the upholstery.

With further reference to FIG. 14B, the woven sheet (13) may be naturalor man-made fibers (such as rayon, nylon cotton or linen fibers) woventogether to form a sheet, and is mounted on one of the surfaces of themultilayer mesh structure (1D, 1E).

With further reference to FIGS. 2, and 3, in a first embodiment of thepresent invention, the multilayer mesh structure (1) has six stackedmesh layers (10) wherein, the thickness of the primary and secondaryfibers (11, 12) of each mesh layer is progressively reduced from onesurface mesh layer (10) to the other surface mesh structure (10), so themultiple breathing holes are also progressively reduced from large tosmall and the primary and secondary fibers (12) are circular incross-section.

With further reference to FIGS. 5, and 6, in a second embodiment of thepresent invention, the multilayer mesh structure (1A) has four stackedmesh layers (10A) wherein, the cross-section of the primary fibers (11)and secondary fibers (12) are rectangles.

With reference to FIG. 8, in a third embodiment of the presentinvention, the multilayer mesh structure (1B) has four mesh layers (10B)wherein, each mesh layer (1B) has alternatively arranged primary fibers(11, 11A) respectively having circular and rectangular cross sectionsand alternatively arranged secondary fibers (12, 12A) respectivelyhaving circular and rectangular cross sections.

With further reference to FIGS. 9 and 10, in a fourth embodiment of thepresent invention, the multilayer mesh structure (1C) has six meshlayers (10, 10A, 10B), wherein, the cross-section of the primary andsecondary fibers (11,12) of one surface mesh layer (10) and the meshlayer (10) adjacent to the surface mesh layer (10) are circles, thecross-sections of the primary and secondary fibers (11,12) of two middlemesh layers (10A) are rectangles, and the other surface mesh layer (10B)and the mesh layer (10B) adjacent to the other surface mesh layer havealternatively arranged primary and secondary fibers (12, 12A)respectively having circular and quadrangular cross sections.

With further reference to FIGS. 13 and 17 the multilayer mesh structure(1D, 1E) may be implemented in a shoe (40). The shoe (40) has an outerupper (41), an inner upper (42), an outsole (43), a sole cushion (44)and innersole (45).

The outer upper (41) corresponds to a foot and has an inner surface anda connecting edge.

The inner upper (42) corresponds to the outer upper (41), is formed onthe inner surface of the outer sheet (41), has a connecting edge andcomprises the multilayer mesh structure (1D). The multilayer meshstructure (1D) has three stacked mesh layers (10) and one woven sheet(13), wherein breathing holes formed between the primary and secondaryfibers (11, 12) of the three mesh layers (10) are progressivelydecreased in size. The woven sheet (13) is attached to the mesh layer(10) having smaller breathing holes.

The outsole (43) is shaped corresponding to a sole of a foot andattached to the connecting edge of the uppers (41, 42).

The sole cushion (44) corresponds to and is formed on the outsole (43).

The innersole (45) corresponds to and is formed on the sole cushion (44)and comprises the multilayer mesh structure (1E). The multiple meshstructure (1E) has three stacked mesh layers (10) and one woven sheet(13), wherein, the breathing holes formed between the primary andsecondary fibers (11, 12) of the three mesh layers (10) are graduallyreduced from outside to in. The woven sheet (13) is attached to the mesh(10) having smaller holes between weft and warp than the breathing holesand is larger than the multilayer mesh structure (1E) to cover and holdthe multilayer mesh structure (1E) in place.

Even though numerous characteristics and advantages of the presentinvention have been set forth in the foregoing description, togetherwith details of the structure and function of the invention, thedisclosure is illustrative only. Changes may be made in detail,especially in matters of shape, size and arrangement of parts within theprinciples of the invention to the full extent indicated by the broadgeneral meaning of the terms in which the appended claims are expressed.

1. A multilayer mesh structure comprising multiple mesh layers beingnon-woven, being stacked on tops of each other and each mesh layerhaving two surfaces; multiple primary fibers being mounted substantiallyparallel to each other and extruded to form at least one cross sectionand at least one thickness; multiple secondary fibers being mountedsubstantially parallel to each other, crossing the primary fibers atbonded intersections and being extruded to form at least one crosssection and at least one thickness; and multiple breathing holes beingformed between the primary and secondary fibers.
 2. The multilayer meshstructure as claimed in claim 1, wherein the primary fibers and thesecondary fibers are circular in cross section.
 3. The multilayer meshstructure as claimed in claim 1, wherein the primary fibers and thesecondary fibers are rectangular in cross section.
 4. The multilayermesh structure as claimed in claim 1, wherein each mesh layer hasalternatively arranged primary fibers respectively having circular andrectangular cross-sections, and alternatively arranged secondary fibersrespectively having circular and rectangular cross-sections.
 5. Themultilayer mesh structure as claimed in claim 1, wherein the multilayermesh structure further has a covering layer being a film to enclose themultiple mesh layers.
 6. The multilayer mesh structure as claimed inclaim 1, wherein the multilayer mesh structure further has a woven sheetbeing formed on one of the surfaces of the multilayer mesh structure. 7.The multilayer mesh structure as claimed in claim 6, wherein the wovensheet is larger than the stacked mesh to cover and hold the multilayermesh structure.
 8. The multilayer mesh structure as claimed in claim 1,wherein the breathing holes of each mesh layer are uniform.
 9. Themultilayer mesh structure as claimed in claim 1, wherein the breathingholes of each mesh layer progressively decrease in size from one surfaceof the multilayer mesh structure to the other surface of the multilayermesh structure.
 10. The multilayer mesh structure as claimed in claim 2,wherein the multilayer mesh structure further has a covering layer beinga film to enclose the multiple mesh layers.
 11. The multilayer meshstructure as claimed in claim 2, wherein the multilayer mesh structurefurther has a woven sheet being formed on one of the surfaces of themultilayer mesh structure.
 12. The multilayer mesh structure as claimedin claim 2, wherein the breathing holes of each mesh layer are uniform.13. The multilayer mesh structure as claimed in claim 2, wherein thebreathing holes of each mesh layer progressively decrease in size fromone surface of the multilayer mesh structure to the other surface of themultilayer mesh structure.
 14. The multilayer mesh structure as claimedin claim 3, wherein multilayer mesh structure further has a coveringlayer being a film to enclose the multiple mesh layers.
 15. Themultilayer mesh structure as claimed in claim 3, wherein the multilayermesh structure further has a woven sheet being formed on one of thesurfaces of the multilayer mesh structure.
 16. The multilayer meshstructure as claimed in claim 3, wherein the breathing holes of eachmesh layer are uniform.
 17. The multilayer mesh structure as claimed inclaim 3, wherein the breathing holes of each mesh layer progressivelydecrease in size from one surface of the multilayer mesh structure tothe other surface of the multilayer mesh structure.
 18. The multilayermesh structure as claimed in claim 1, wherein each mesh is elastic, isbreathable and is mildew growth preventing.
 19. The multilayer meshstructure as claimed in claim 1, wherein each mesh is thermoplasticelastomer or thermoplastic plastic.
 20. The multilayer mesh structure asclaimed in claim 1, wherein the meshes are bonded to each other bysewing or adhesion.